# US 10,871,037 B2 · Mechanical locking of ovoid cutting element with carbide matrix

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- Number: US 10,871,037 B2
- Document ID: US10871037B2
- Status: Granted
- Kind: B2
- Application number: 16/061,694
- Filed: 2016-12-14
- Published: 2018-12-20
- Granted: 2020-12-22
- Earliest claimed: 2015-12-14
- Assignees: Smith International, Inc.
- Applicants: Smith International, Inc.
- Inventors: Ryan Worth Eldredge; Gregory Caron; Jeffrey Bruce Lund
- Web page: https://patentgrep.com/patent/US10871037B2

## CPC

- E21B 10/55: with preformed cutting elements
- E21B 10/42: Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits (characterised by wear resisting parts E21B10/46; by conduits or nozzles for drilling fluid E21B10/60; by detachable or adjustable parts E21B10/62)
- E21B 10/485: {with inserts in form of chisels, blades or the like}
- E21B 10/54: the bit being of the rotary drag type, e.g. fork-type bits
- E21B 10/5676: {having a cutting face with different segments, e.g. mosaic-type inserts}
- E21B 10/573: characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element
- E21B 10/58: Chisel-type inserts ({E21B10/485,} E21B10/52 take precedence)
- E21B 10/633: independently detachable
- B23P 15/28: cutting tools (sawing tools B23D63/00, B23D65/00; files or rasps B23D73/00)
- E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)

## Abstract

A cutting assembly for use in a drill bit has an ovoid insert including an ultrahard material. The ovoid insert is cast in a matrix such that the matrix surrounds at least part of the ovoid insert, limiting movement of the ovoid insert. Material is removed from the top surface and sidewall of the cutting assembly to produce a cutting edge.

## Claims

### Claim 1

A cutting assembly for use in a drill bit comprising:
a matrix including a matrix material;
an insert embedded in the matrix, the insert including an ultrahard material, the insert having an ovoid contact surface, the matrix encapsulating the insert by at least 50% in at least one axis to restrain the insert in the matrix, wherein the matrix is positioned proximate the insert at the ovoid contact surface;
a front surface, the insert and the matrix being exposed on the front surface, an insert front surface being curved in a first direction along the front surface and straight in a second direction along the front surface; and
a top surface, a first end surface of the insert being exposed on the top surface and the matrix being exposed on the top surface, the first end surface on the top surface being planar, wherein a width of the insert increases from the top surface into the matrix along the at least one axis.

### Claim 2 (depends on 1)

The cutting assembly of claim 1, the matrix material being a brazable material.

### Claim 3 (depends on 1)

The cutting assembly of claim 1, the insert and the matrix directly contacting one another.

### Claim 4 (depends on 1)

The cutting assembly of claim 1, further comprising an arcuate cutting edge between the front surface and the first end surface.

### Claim 5 (depends on 1)

The cutting assembly of claim 1, the insert further comprising a planar second end surface opposite the first end surface.

### Claim 6 (depends on 1)

The cutting assembly of claim 1, the insert further comprising a rear surface curved in the first direction and planar in the second direction, the rear surface being opposite the front surface.

### Claim 7 (depends on 1)

The cutting assembly of claim 1, further comprising a binder layer positioned between the insert and the matrix.

### Claim 8 (depends on 1)

The cutting assembly of claim 1, the insert being exposed on a sidewall of the matrix and a top surface of the matrix.

### Claim 9

A method of manufacturing a cutting assembly for use in a drill bit, the method comprising:
providing an ovoid insert including an ultrahard material;
casting the ovoid insert into a matrix substantially encapsulating at least a portion of the ovoid insert;
grinding a top surface of the ovoid insert and the matrix; and
grinding a sidewall of the ovoid insert and the matrix.

### Claim 10 (depends on 9)

The method of claim 9, further comprising grinding a bottom surface of the ovoid insert and the matrix.

### Claim 11 (depends on 9)

The method of claim 9, wherein the grinding the sidewall somprises grinding a front surface of the insert and grinding an opposing rear surface of the ovoid insert.

### Claim 12 (depends on 9)

The method of claim 9, providing an ovoid insert including casting the ovoid insert from a precursor having a first portion and a second portion joined during casting.

### Claim 13 (depends on 9)

The method of claim 9, wherein grinding the top surface includes grinding the ovoid insert and the matrix to expose a top portion of the ovoid insert on the top surface and wherein grinding the sidewall includes grinding the ovoid insert and the matrix to expose a side portion of the ovoid insert on the sidewall.